Smokeless tobacco article

ABSTRACT

A method for making a smokeless tobacco article can include combining thermoplastic polymer particles with tobacco particles to form a mixture of particles, compressing the mixture of particles within a pressing apparatus to form the mixture into a predetermined shape, separating the mixture from the pressing apparatus such that it retains the predetermined shape, and heating the mixture outside of the pressing apparatus to at least partially melt at least some of the thermoplastic polymer particles and form a matrix of polymer and tobacco particles.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 14/204,530, filed onMar. 11, 2014, which claims the benefit of priority under 35 U.S.C.§119(e) to U.S. Application No. 61/786,252 filed Mar. 14, 2013. Theprior applications are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

This document relates to tobacco products and methods for makingsmokeless tobacco articles.

BACKGROUND

Tobacco compositions are available to adult tobacco consumers in avariety of forms. Smoking tobacco is combusted and the aerosol eithertasted or inhaled (e.g., in a cigarette, cigar, or pipe). Smokelesstobacco articles are not combusted and include: chewing tobacco, moistsmokeless tobacco, snus, and dry snuff. Chewing tobacco is coarselydivided tobacco leaf that is typically packaged in a large pouch-likepackage and used in a plug or twist. Moist smokeless tobacco is a moist,more finely divided tobacco that is provided in loose form or in pouchform and is typically packaged in round cans and used as a pinch or in apouch placed between a cheek and gum of an adult tobacco consumer. Snusis a heat treated smokeless tobacco. Dry snuff is finely ground tobaccothat is placed in the mouth or used nasally.

SUMMARY

Methods for forming smokeless tobacco articles and the resultingsmokeless tobacco articles are provided herein. Methods provided hereincan include combining thermoplastic polymer particles with tobaccoparticles to form a mixture of particles, compressing the mixture ofparticles within a pressing apparatus to form the mixture into apredetermined shape, releasing pressure on the mixture such that themixture retains the predetermined shape, and heating the mixture to atleast partially melt at least some of the thermoplastic polymerparticles and form a matrix of polymer and tobacco particles. In somecases, a compressed mixture of particles having the predetermined shapeis ejected from the pressing apparatus prior to heating the mixturehaving the predetermined shape. The heating of the mixture having apredetermined shape can take place in a convection oven. A resultingsmokeless tobacco article can have a soft mouth feel and provide anadult tobacco consumer a satisfying tactile and/or flavor experience.The methods provided herein can yield high production speed for eachpressing cavity. The smokeless tobacco article can include a body thatis at least partially receivable in an oral cavity of an adult tobaccoconsumer. In some cases, cellulosic fibers can be included in thesmokeless tobacco article. In some cases, a combination of cellulosicfibers and one or more tobacco organoleptic compounds can be included inthe smokeless tobacco article in addition to or in place of tobaccoparticles.

Smokeless tobacco articles provided herein can each optionally includeone or more of the following features. A smokeless tobacco article bodyprovided herein can have a Shore M durometer of at least 89 (e.g., atleast 90, at least 91, or at least 92). The amount of compression, theheating time, and the heating temperature can all impact the Shore Mhardness. In some cases, the mixture of particles is compressed with atleast 4 kN (e.g., at least 5 kN, at least 6 kN, at least 7 kN, or atleast 8 kN). In some cases, the compressed mixture of particles having apredetermined shape is heated in an oven having a temperature less than20° C. greater than the melting temperature of the thermoplasticpolymer. In some cases, the oven can have a temperature that is lessthan 15° C. greater than the melting temperature of the thermoplasticpolymer, less than 10° C. greater than the melting temperature of thethermoplastic polymer, or less than 5° C. greater than the meltingtemperature of the thermoplastic polymer. For example, a ultrahighmolecular weight polyethylene (UHMWPE) polymer can have a meltingtemperature of about 144° C. and an oven used to heat a mixtureincluding UHMWPE particles can have an internal temperature of about150° C. In some cases, UHMWPE polymer is exposed to a temperature of150° C. or less for between 20 minutes and 30 minutes. The compressedmixture of particles having a predetermined shape can be heated for atime period of between 5 minutes and 1 hour (e.g., between 10 minutesand 50 minutes, between 15 minutes and 45 minutes, between 20 minutesand 40 minutes, or between 25 minutes and 35 minutes).

A smokeless tobacco article body provided herein can include at least 30weight percent of a thermoplastic polymer (e.g., at least 50 weightpercent thermoplastic polymer, at least 55 weight percent thermoplasticpolymer, at least 60 weight percent thermoplastic polymer, at least 65weight percent thermoplastic polymer, or at least 70 weight percentthermoplastic polymer). A smokeless tobacco article body provided hereincan include up to 90 weight percent of a thermoplastic polymer (e.g., upto 80 weight percent thermoplastic polymer, up to 70 weight percentthermoplastic polymer, up to 60 weight percent thermoplastic polymer, upto 50 weight thermoplastic polymer, or up to 40 weight percentthermoplastic polymer). In some cases, the smokeless tobacco article caninclude between 50 weight percent and 70 weight percent thermoplasticpolymer.

The thermoplastic polymer can be a mouth-stable polymer. Themouth-stable polymer matrix can include polyethylene, polypropylene,polyurethane, silicon polymer, polyester, polyacrylate, polyethylene,poly(styrene-ethylene-butylene-styrene) (“SEBS”),poly(styrene-butadiene-styrene) (“SBS”), and other similar thermoplasticelastomers, or any copolymer, mixture, or combination thereof. Thesmokeless tobacco article can also include a plasticizer dispersed inthe mouth-stable polymer matrix. For example, the plasticizer can bepropylene glycol, glycerin, vegetable oil, triglycerides, or acombination thereof. The smokeless tobacco article can also include asweetener dispersed in the body. The sweetener can be saccharine,sucralose, aspartame, acesulfame potassium, or a combination thereof.

Methods provided herein can include mixing thermoplastic polymerparticles with tobacco and compressing the mixture. Thermoplasticpolymer particles used in a method provided herein can have a particlesize of less than 500 μm (e.g., less than 250 μm, less than 100 μm, lessthan 75 μm, less than 50 μm, less than 25 μm, less than 10 μm, less than5 μm, or less than 1 μm). Thermoplastic polymer particles used in amethod provided herein can have a particle size of at least 0.1 μm(e.g., at least 0.5 μm, at least 1 μm, at least 5 μm, at least 10 μm, atleast 25 μm, at least 50 μm, at least 75 μm, or at least 100 μm). Forexample, the thermoplastic polymer particles can have an averageparticle size of between about 1 μm and 100 μm.

Smokeless tobacco articles provided herein can include one or moreadditives. For example, a smokeless tobacco article provided herein caninclude an additive selected from the group consisting of minerals,vitamins, dietary supplements, nutraceuticals, energizing agents,soothing agents, amino acids, chemesthic agents, antioxidants,botanicals, teeth whitening agents, therapeutic agents, or a combinationthereof.

A smokeless tobacco article body provided herein can have at least 10weight percent smokeless tobacco. A smokeless tobacco article bodyprovided herein includes at least 10 weight percent of a smokelesstobacco (e.g., at least 20 weight percent smokeless tobacco, at least 30weight percent smokeless tobacco, at least 40 weight percent smokelesstobacco, at least 50 weight percent smokeless tobacco, or at least 60weight percent smokeless tobacco). A smokeless tobacco article bodyprovided herein can include up to 70 weight percent of a smokelesstobacco (e.g., up to 60 weight percent smokeless tobacco, up to 50weight percent smokeless tobacco, up to 40 weight percent smokelesstobacco, up to 30 weight thermoplastic polymer, or up to 20 weightpercent smokeless tobacco). In some cases, the smokeless tobacco articlecan include between 30 weight percent and 50 weight percent smokelesstobacco. In some cases, the smokeless tobacco can have an averagediameter of between 40 microns to 710 microns. In some cases, asmokeless tobacco article provided herein can include non-tobaccocellulosic fibers. For example, the cellulosic fibers can be selectedfrom the following: sugar beet fiber, wood pulp fiber, cotton fiber,bran fiber, citrus pulp fiber, grass fiber, willow fiber, poplar fiber,and combinations thereof. The non-tobacco cellulosic fibers may also bechemically treated prior to use. For example, the non-tobacco cellulosicfibers can be CMC, HPMC, HPC, or other treated cellulosic material. Insome cases, other additives (e.g., binders) can be used to assist thepiece in maintaining its shape when removed from the press mold cavityprior to sintering.

A smokeless tobacco article provided herein can include flavorants. Theflavorants can be natural or artificial. Flavorants can be selected fromthe following: licorice, wintergreen, cherry and berry type flavorants,Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender,cinnamon, cardamon, apium graveolents, clove, cascarilla, nutmeg,sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemonoil, orange oil, Japanese mint, cassia, caraway, cognac, jasmin,chamomile, menthol, ylangylang, sage, fennel, piment, ginger, anise,coriander, coffee, mint oils from a species of the genus Mentha, cocoa,and combinations thereof. Synthetic flavorants can also be used. Theparticular combination of flavorants can be selected from the flavorantsthat are generally recognized as safe (“GRAS”) in a particular country,such as the United States. Flavorants can also be included in thesmokeless tobacco article as encapsulated flavorants.

The body of the smokeless tobacco article can have a variety ofdifferent shapes, some of which include disk, shield, rectangle,triangle, oval and square. In some cases, the body can have a length orwidth of between 5 mm and 25 mm and a thickness of between 1 mm and 10mm.

The details of one or more embodiments of the subject matter describedin this specification are set forth in the accompanying drawings and thedescription below. Other features, aspects, and advantages of thesubject matter will become apparent from the description, the drawings,and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a smokeless tobacco article providedherein.

FIGS. 2A-2E illustrate methods of making smokeless tobacco articlesprovided herein.

FIG. 3 is a perspective view of a pressing apparatus used to compress amixture of thermoplastic polymer particles and smokeless tobacco.

FIGS. 4A-4D illustrate exemplary rounded rectangle shapes of smokelesstobacco articles provided herein.

FIGS. 5A-5D illustrate exemplary rounded triangle shapes of smokelesstobacco articles provided herein.

FIGS. 6A-6B and FIGS. 7A-7L illustrate various additional exemplaryshapes of smokeless tobacco articles.

FIG. 8A-8J illustrate smokeless tobacco articles having various rod,stick, or tube configurations.

FIG. 9 is a chart depicting the Shore M hardness of various exemplarypieces.

DETAILED DESCRIPTION

This document provides materials and methods for making smokelesstobacco articles in which a combination of tobacco particles and plasticpolymer particles are combined, compressed, and heated to form asmokeless tobacco article. The resulting smokeless tobacco article canprovide an adult tobacco consumer with a good mouth feel and a pleasingflavor. Smokeless tobacco articles provided herein can be less expensiveto manufacture than traditional pouch smokeless tobacco articles, andcan have a longer shelf life because they are substantially dry, ratherthan wet or moist. For example, a smokeless tobacco article providedherein can have an extended shelf life (e.g., 30 weeks or more). Themethods provided herein can allow for a high throughput per compressioncavity.

Smokeless tobacco articles provided herein can include a porous matrixformed from particles of a thermoplastic polymer and tobacco dispersedwithin the pores of the porous matrix. Smokeless tobacco articlesprovided herein can include air spaces between the polymer and thetobacco. The size of the polymer particles can affect the size of thepores that result from the processes provided herein, such that largerparticles typically result in larger pores, and smaller particles resultin smaller pores. Larger pores can result in faster desorption oftobacco and tobacco components from an article, while smaller pores canresult in slower desorption. The rate of tobacco desorption thus can bemoderated based on the pore size. Various sizes of polymer particles canbe used. For example, smokeless tobacco articles provided herein can bemade from polymer particles having an average diameter of about 1microns to about 100 microns (e.g., about 1 micron, about 5 microns,about 10 microns, about 20 microns, about 30 microns, about 40 microns,about 50 microns, about 60 microns, about 70 microns, about 80 microns,about 90 microns, or about 100 microns), or any range in between,including, without limitation, about 1 to about 10 microns, about 10microns to about 20 microns, about 15 microns to about 25 microns, about20 microns to about 30 microns, about 30 microns to about 40 microns,about 40 microns to about 50 microns, about 50 microns to about 60microns, about 60 microns to about 80 microns, or about 80 microns toabout 100 microns. Smokeless tobacco articles provided herein can haveaverage void diameters of about 1 to about 50 microns, or any range inbetween, including, without limitation, about 1 microns to about 5microns, about 3 microns to about 15 microns, about 10 microns to about20 microns, about 20 microns to about 30 microns, about 30 microns toabout 40 microns, or about 40 microns to about 50 microns. Smokelesstobacco articles provided herein can have different regions withdifferent average pore sizes. For example, the resulting smokelesstobacco article can have a gradient of average pore sizes from a surfacehaving a smaller average pores size to a central portion having a largeraverage pore size. Average pore sizes can be measured by taking across-section of the article and measuring, with a microscope, thelargest dimension of each observable pore between fused polymerparticles and averaging the observed largest dimensions. The resultingvoid volume can also depend upon the dimensions of the fused polymerparticles. In some cases, smokeless tobacco articles provided herein canhave different regions having different void volumes. For example, theresulting article can have a gradient of void volume from a surfacehaving a smaller void volume to a central portion having a larger voidvolume.

The polymer particles can include regularly and irregularly sized andshaped particles. In some cases, the polymer particles can besubstantially spherical (e.g., round beads). In some cases, irregularlyshaped polymer granules of various sizes can be used. In some cases, thepolymer particles can include flakes, cylindrical beads, films withdifferent cut lengths, polymer shavings, chunks, and polymer fibers cutto various lengths. The shape of the polymer particles can impact theaverage pore sizes, the pore size distribution, and the void volume.

A number of materials are suitable for the porous matrix of a smokelesstobacco article provided herein. For example, a porous matrix cancomprise a porous, insoluble thermoplastic such as polyethylene.Ultra-high molecular weight polyethylene can be particularly usefulbecause, for example, the particle size of ultra-high molecular weightpolyethylene beads can be readily controlled. In addition, the use ofultra-high molecular weight polyethylene can result in a particularlysmooth product, which can feel malleable in the mouth of a consumer.

A porous matrix additionally or alternatively can include one or more ofthe following polymer materials: acetals, acrylics such aspolymethylmethacrylate and polyacrylonitrile, alkyds, polymer alloys,allyls such as diallyl phthalate and diallyl isophthalate, amines suchas urea, formaldehyde, and melamine formaldehyde, cellulosics such ascellulose acetate, cellulose triacetate, cellulose nitrate, ethylcellulose, cellulose acetate propionate, cellulose acetate butyrate,hydroxypropyl cellulose, cellophane and rayon, chlorinated polyether,coumarone-indene, epoxy, fluorocarbons such as PTFE, FEP, PFA, PCTFE,ECTFE, ETFE, PVDF, and PVF, furan, hydrocarbon resins, nitrile resins,polyaryl ether, polyaryl sulfone, phenol-aralkyl, phenolic, polyamide(nylon), poly (amide-imide), polyaryl ether, polycarbonate, polyesterssuch as aromatic polyesters, thermoplastic polyester, PBT, PTMT, PET andunsaturated polyesters such as SMC and BMC, polyimides such asthermoplastic polyimide and thermoset polyimide, polymethyl pentene,polyolefins such as LDPE, LLDPE, and HDPE, polypropylene, inomers suchas PD and poly allomers, polyphenylene oxide, polyphenylene sulfide,polyurethanes, poly p-xylylene, silicones such as silicone fluids andelastomers, rigid silicones, styrenes such as PS, ADS, SAN, styrenebutadiene lattices, and styrene based polymers, sulfones such aspolysulfone, polyether sulfone and polyphenyl sulfones, thermoplasticelastomers, and vinyls such as PVC, polyvinyl acetate, polyvinylidenechloride, polyvinyl alcohol, polyvinyl butyrate, polyvinyl formal,propylene-vinyl chloride copolymer, ethylvinyl acetate, and polyvinylcarbazole. In addition, the polymer or polymers from which a porousmatrix is made can be colored, resulting in a colored smokeless tobaccoarticle.

The tobacco particles contained in the smokeless tobacco articlesprovided herein can be granulated, powdered, flaked, shredded, cut(e.g., long cut tobacco), cured, aged, fermented, heat treated,pasteurized, encapsulated, or otherwise processed. Powdered, granulated,or flaked tobacco can be particularly useful. For example, tobacco canbe in a granulated or powdered form so that it is sized to fit withinthe pores of a porous matrix. In some cases, some or all of the tobaccoin a smokeless tobacco article can be processed from reconstitutedtobacco. In some cases, the tobacco can be long cut tobacco having alength of about 0.25 inches to 1 inch and a width of between 0.005inches to 0.05 inches. For example, tobacco can include between 35 cutsper inch. In some cases, long cut tobacco can be retained in a centralportion of the article and a peripheral portion of the article can besubstantially free of the long cut tobacco. In some cases, the articlecan include different combinations of different shaped of tobacco,optionally in different portions of the article. For example, asmokeless tobacco article having a central portion including long cuttobacco can also include powdered tobacco in other portions of thesmokeless tobacco article, for example in peripheral portion of thearticle having a smaller average pore size than the central portion.Having an exterior portion of the smokeless tobacco article having asmaller average pore size can also prevent the migration of largertobacco pieces in a central portion of the article from migrating out ofthe polymer matrix.

Tobacco particles can be separated into different size ranges usingmethods known in the art, including mesh screening, for example.Further, a variety of sizes of tobacco particle can be used in thearticles provided herein. For example, a smokeless tobacco article cancomprise tobacco granules, powder, or flakes having an average tobaccoparticle diameter or width of about 20 microns to about 100 microns(e.g., about 20 microns, about 30 microns, about 40 microns, about 50microns, about 60 microns, about 70 microns, about 80 microns, about 90microns, or about 100 microns), or any range in between (e.g., about 20microns to about 40 microns, about 40 microns to about 60 microns, orabout 60 microns to about 100 microns). Tobacco particles having anaverage diameter or width of about 40 microns to about 60 microns can beparticularly useful, as such particles can be readily obtained and canresult in a tobacco product having a smooth, non-gritty texture. Where agrittier texture is desired, particles having an average diameter ofabout 60 microns to about 100 microns can be used. The size of tobaccoparticles can be modified based on a milling process (e.g., hammermilling). The different types of tobacco used in the smokeless tobaccoarticles provided herein are discussed in further detail below.

Tobacco (e.g., granulated, powdered, flaked tobacco particles, or longcut tobacco) can be combined with polymer material at a selected ratio,and the mixture can then be used in molding processes (as described, forexample, in connection with FIGS. 2A, 2B, and 2C). Typically, theproducts provided herein contain from about 30% to about 60% tobacco byweight, such that the ratio of tobacco:polymer ranges from about 30:70to about 60:40 (e.g., about 40:60, about 45:55, or about 50:50).Alternatively, the tobacco products provided herein can contain fromabout 20% to about 80% tobacco by weight, such that the ratio oftobacco:polymer ranges from about 20:80 to about 70:30 (e.g., about20:80, about 45:55, about 50:50, about 60:40, or about 70:30). A ratioof tobacco:polymer that is relatively low may result in a product thatis perceived to be hard, while a ratio that is relatively high mayresult in loss of structural integrity, and can result in a product thatis perceived to be soft.

The sizes of the tobacco particles and the polymer particles relative toone another can be varied. Typically, however, when relatively largetobacco particles (e.g., 60 microns to 100 microns in diameter, onaverage) are used, bigger polymer particles can be used so that theresulting product has sufficient structural integrity. When relativelysmall tobacco particles (e.g., 40 microns to 60 microns in diameter, onaverage) are used, smaller polymer particles (e.g., 10 microns to 20microns in diameter, on average) also can be used. The size of thetobacco and polymer particles can affect the texture of the resultingsmokeless tobacco article. For example, smaller particles can result ina smoother product, while larger particles can give a rougher orgrittier product. Thus, the smokeless tobacco articles provided hereincan be manufactured to a variety of texture profiles.

The smokeless tobacco articles provided herein can have a variety ofshapes (e.g., rectangular, square, spherical, cylindrical, rod shapedarticle being comfortable for placement in a mouth of an adult tobaccoconsumer). In some cases, a smokeless tobacco article can be adapted tobe wholly received by an adult consumer. Such smokeless tobacco articlescan be configured to nearly unlimited forms. For example, smokelesstobacco articles provided herein can be configured to resemble a tobaccopouch, and can have a generally elliptical shape, but other embodimentscan have a pillow shape, a boat-like shape, a circular shape, a flatrectangular shape, or the like. Further, smokeless tobacco articlesprovided herein can be formed or molded over a non-disintegratablesubstrate.

The article can also include accumulated granules of tobacco powder,sugars, starches, and/or flavors. Tobacco containing accumulatedgranules can be included in the article as the tobacco or along withother tobacco. For example, U.S. patent application Ser. No. 12/641,915,filed Dec. 18, 2009, entitled “Tobacco Granules and Method of ProducingTobacco Granules,” which is hereby incorporated by reference, describesaccumulated granules including tobacco particles. The granules caninclude a core and one or more layers surrounding the core that includestobacco particles and a binder. In some cases, the accumulated granulescan be coated with a polymer and used in the methods provided herein asthe polymer particles, either without additional solid polymer particlesor with additional solid polymer particles making up the polymer matrix.In some cases, the accumulated granules can be fully encapsulated by thepolymer. In some cases, the accumulated granules can include anincomplete coating that allows for tobacco, flavors, and/or otherconstituents to migrate though the network of pores in the article.During use, flavors and/or tobacco constituents of the accumulatedgranules can elute though the porous network of the article to bereleased into a mouth of an adult tobacco consumer. In some cases,mastication of the article can result in the release of flavorants fromencapsulated accumulated granules within the smokeless tobacco article.Accumulated granules, such as the tobacco granules described in U.S.patent application Ser. No. 12/641,915, can be coated with polymeraccording to known techniques in the art, including painting,sputtering, and drum coating processes.

Turning now to the Figures, smokeless tobacco article 100 as depicted inFIG. 1 can include porous matrix 110, with tobacco particles 120disposed in pores 112 of porous matrix 110 so that smokeless tobaccoarticle 100 can provide, for example, tobacco to an adult consumer. Asdescribed herein, smokeless tobacco article 100 can furnish tobaccosatisfaction to the adult tobacco consumer.

Smokeless tobacco article 100 can be a noncombustible product, insofaras article 100 does not require ignition during use. Smokeless tobaccoarticle 100 can provide tobacco to a consumer without combusting anypart of smokeless tobacco article 100, and without igniting tobacco 120inside article 100. Rather, the noncombusted tobacco can be provided tothe consumer to provide tobacco satisfaction in the form of anexperience associated with tobacco components, organoleptic components,and added flavor components that are released upon usage. Suchorganoleptic components can relate or contribute to the integratedsensory perception by the consumer that includes, for example, anycombination of aroma, fragrance, flavor, taste, odor, mouth feel, or thelike.

Suitable mouth-stable polymers include thermoplastic elastomers such aspolyethylene and/or polyurethane. As used here, the term “mouth stable”means that the polymer does not appreciably dissolve or disintegratewhen exposed to saliva within an oral cavity and at the normal humanbody temperature (e.g., about 98.6° F.) over a period of one hour. Inaddition to biostable polymers, mouth-stable polymers can includebiodegradable polymers that breakdown over periods of days, weeks,months, and/or years, but do not appreciably break down when held in anoral cavity and exposed to saliva for a period of one hour. In somecases, the mouth-stable polymer is stable within an oral cavity andexposed to saliva at the normal human body temperature for a period ofat least 6 hours, at least 12 hours, at least 24 hours, or at least 2days. Accordingly, the smokeless tobacco articles provided herein canremain intact when placed within an oral cavity during a use period.After use, the mouth-stable polymer matrix can be removed from the oralcavity and discarded.

One or more additives can be included in the smokeless tobacco articleand adapted to be released from the smokeless tobacco article when thesmokeless tobacco article is placed in an oral cavity of adult tobaccoconsumer. The smokeless tobacco articles provided herein can includeadded nicotine and/or other additives. During use, saliva can beabsorbed into the polymer matrix to release the tobacco constituents.Mechanical action (e.g., chewing) of the smokeless tobacco article canfacilitate the release of the additives, sweeteners, and/or flavorants.

In addition to additives, sweeteners, and flavorants, the smokelesstobacco article can also include fillers, plasticizers, and/orprocessing aids. Fillers can also be included in the mouth-stablepolymer matrix to alter the texture or pliability of the smokelesstobacco article. The mouth-stable polymer matrix can also includeplasticizers, which can increase the softness of the smokeless tobaccoarticle. Non-tobacco cellulosic fibers can also be included to alter theproperties of the smokeless tobacco article. Processing aids can also bepresent in the smokeless tobacco article.

Producing a Smokeless Tobacco Article

FIGS. 2A-2C illustrate methods of making smokeless tobacco articlesprovided herein. A method for making a smokeless tobacco articleprovided herein can include combining thermoplastic polymer particleswith tobacco particles to form a mixture of particles, compressing themixture of particles within a pressing apparatus to form the mixtureinto a predetermined shape, releasing pressure on the mixture such thatthe mixture retains the predetermined shape, and heating the mixture toat least partially melt at least some of the thermoplastic polymerparticles and form a matrix of polymer and tobacco particles. In somecases, the mixture having the predetermined shape is removed from thepressing apparatus prior to being heated.

The compression of the mixture can take place in a mold, such as thatdescribed below in reference to FIG. 3. For example, the mold shown inFIG. 3 can be used in the process diagrammed in FIG. 2A. The amount ofcompression can impact the final properties of the smokeless tobaccoarticle. In some cases, the mixture is compressed with a force of atleast 4 kN (e.g., at least 5 kN, at least 6 kN, at least 7 kN, or atleast 8 kN). In some cases, the mixture is compressed with a force ofbetween 4 kN and 15 kN (e.g., between 5 kN and 10 kN, between 6 kN and 9kN, or between 7.5 kN and 8.5 kN). The mixture can be compressed at atemperature that is below the melting temperature of the polymerparticles. In some cases, the temperature in the pressing apparatus canbe less than 100° C. (e.g., less than 80° C., less than 70° C., lessthan 60° C., less that 50° C., less than 40° C., or less than 30° C. Insome cases, the temperature in the pressing apparatus during the processof compressing the mixture is approximately room temperature (betweenabout 20° C. and about 25° C.). The compression of the mixture into thepredetermined shape can take less than 1 minute (e.g., less than 30seconds, less than 15 seconds, less than 10 seconds, less than 5seconds, or less than 3 seconds). In some cases, a pressing apparatuscan compress at least 5 units per minutes (e.g., at least 10 units perminute, at least 15 units per minute, or at least 20 units per minutes)for each pressing cavity.

After a mixture of particles is compressed into a predetermined shape,pressure is released in the cavity of the pressing apparatus. In somecases, each compressed mixture is ejected from the pressing cavity andsent to an oven. The compressed mixture retains its predetermined shapeduring ejection and transport to the oven. The oven can be a convectionoven heated to a temperature above the melting temperature of thepolymer particles in the compressed mixture. In some case, the oven hasan internal temperature of less than 20° C. (e.g., less than 15° C.,less than 10° C., or less than 5° C.) greater than the meltingtemperature of the polymer particles in the compressed mixture. Eachcompressed mixture can be placed in the oven for between 5 minutes and 1hour (e.g., between 10 minutes and 50 minutes, between 15 minutes and 45minutes, between 20 minutes and 40 minutes, or between 25 minutes and 35minutes). The time in the oven and the temperature of the oven canimpact the Shore M hardness, as discussed below in reference to FIG. 9.

Referring specifically to FIG. 2A, a smokeless tobacco article can bemade using a mixture of UHMWPE (ultra-high molecular weightpolyethylene) having a particle size of about 180 μm. The UHMWPE canhave a melting temperature of about 144° C. The tobacco can be powderedtobacco that passes through a 400 mesh. The polymer powder and thetobacco powder are mixed in a powder mixing process 210. In some cases,the weight ratio of polymer to tobacco is between 1:1 and 5:1. In somecases, the weight ratio of polymer to tobacco is about 2:1. The mixtureof polymer powder and tobacco is then compact molded in step 220 at aforce of greater than about 1 kN. For example, it can be compacted atabout 1,000 lbs. (i.e., about 4.45 kN) at room temperature (i.e.,between about 20° C. and 25° C.). The compact molding process compressesthe mixture of particles such that the mixture retains a predeterminedshape. This can take about 1 to about 5 seconds. The predetermined shapeand the compact molding apparatus are then placed in an oven for athermal treatment in step 230. The oven can be operated at atmosphericpressure. The oven can have forced convection and have an internal oventemperature of about 150° C. The predetermined shape can be heated forabout 20 minutes and then cooled at room temperature in step 240 forabout 5 to 10 minutes to form a smokeless tobacco article having tobaccowithin a porous matrix of UHMWPE.

FIG. 2B depicts an arrangement where a powder mixture is heated in thepressing apparatus (e.g., the platen). As shown in FIG. 2B, the polymerpowder and the tobacco are mixed in step 212 and delivered to a pressingapparatus 222 (e.g., the platen). In step 223, the mold cavity is filledwith 300 mg of the mixture. The mixture is then tamped at about 6 lbs.force and heated at about 150° C. for about 30 minutes in step 232 inthe pressing apparatus 222. The mixture can then be cooled in step 242and ejected in step 243. In some cases, the mixture is cooled inside ofthe pressing apparatus 222 for about 5 minutes prior to ejection. Insome cases, the mixture is ejected and then cooled for about 15 minutesunder ambient conditions. As shown, this process can have a cycle timeof about 45 minutes per piece in the pressing apparatus and thus yieldabout 108 pieces per day for a pressing apparatus having 6 pressingcavities.

FIG. 2C depicts an arrangement where the powder mixture is ejected fromthe pressing apparatus 225 (e.g., the tablet press) and heated in anoven 235. As shown in FIG. 2C, the polymer powder and the tobacco aremixed in step 215 and delivered to a pressing apparatus 225 (e.g., thetablet press). In step 226, the mold cavity is filled with 300-800 mg ofthe mixture. The mixture is then pressed at about 400 lbs. force (i.e.,about 1.78 kN) to form the mixture into a predetermined shape. Themixture can then be ejected from the mold cavity in step 228 having apredetermined shape. The piece having a predetermined shape can then beconveyed to oven 235 for a thermal cycle 236. The oven can have atemperature of about 155° C. and the pieces having the predeterminedshape can stay in the oven for about 40 minutes. The pieces can then becooled in step 245 under ambient conditions for 15-30 minutes. Under theprocess depicted in FIG. 2C, the pressing apparatus 225 can produceabout 20 pieces per minute, thus a single pressing apparatus can produceabout 7,200 pieces per shift.

FIG. 2D depicts a method where ultrahigh molecular weight polyethylene(UHWMPE) and silica are sintered and tobacco and flavorants are absorbedinto the matrix. FIG. 2E depicts a method where polyurethane and otheringredients are mixed and sintered followed by having tobacco andflavorants absorbed into the matrix.

FIG. 3 is a perspective view of an exemplary molding apparatus 300,which can be used in the methods provided herein (e.g., in the method ofFIG. 2A). The pressing apparatus 300 can have a mold body 310 defining apressing cavity 312 therein. A bottom of the pressing cavity 312 can beformed by a bottom mold insert part 340, which couples to the mold body310. The mold body 310 and the bottom mold insert 340 can attach to themold base 330. The mold base 330 can include apertures to draw a vacuumon in the mold cavity 312. A top mold insert 320 can be used to form thetop of the pressing cavity 312 as well as to press a mixture ofparticles within the mold cavity 312. The bottom mold part 330 can beseparated from the mold body 310 to allow for the pressed mixture to beejected from the mold body 310 by further extending the top mold insert320.

Smokeless Tobacco Article Shapes and Packaging

FIG. 1 depicts an example of a smokeless tobacco article 100. Thesmokeless tobacco article 100 has a rectangular shape. Referring now toFIGS. 4A-4D, 5A-5D, 6A, 6B, 7A-7L, and 8A-8J, the smokeless tobaccoarticle 100 can be molded into any desired shape.

FIGS. 4A-4D depict smokeless tobacco articles having rectangular shapeswith rounded corners. As shown in FIGS. 4A-4D, the smokeless tobaccoarticles provided herein can have textured surfaces. FIG. 4A depicts araised cross-hatched surface. FIGS. 4B-4D depict smokeless tobaccoarticles having a serrated texture. These surface textures can beproduced during the pressing process and retained during the heatingprocess. The smokeless tobacco articles can be pressed to have anydesired texture or a design. For example, a smokeless tobacco articlecan be pressed with any type of design including, but not limited to, atrademark, a product name, or any type of image.

FIGS. 5A-5D depict smokeless tobacco articles having triangular shapeswith rounded corners and an orifice. As shown, the orifices in FIGS.5A-5D can different dimensions. FIG. 6A depicts a leaf shape. FIG. 6Bdepicts an almond shape.

Referring to FIGS. 7A-7L, the smokeless tobacco article 100A-L can beformed in a shape that promotes improved oral positioning in the oralcavity, improved packaging characteristics, or both. In somecircumstances, the smokeless tobacco article 100A-L can be configured tobe: (A) an elliptical-shaped smokeless tobacco article 100A; (B) anelongated elliptical-shaped smokeless tobacco article 100B; (C)semi-circular smokeless tobacco article 100C; (D) square orrectangular-shaped smokeless tobacco article 100D; (E) football-shapedsmokeless tobacco article 100E; (F) elongated rectangular-shapedsmokeless tobacco article 100F; (G) boomerang-shaped smokeless tobaccoarticle 100G; (H) rounded-edge rectangular-shaped smokeless tobaccoarticle 100H; (I) teardrop- or comma-shaped smokeless tobacco article100I; (J) bowtie-shaped smokeless tobacco article 100J; (K)peanut-shaped smokeless tobacco article 100K; and (L) shield-shapedsmokeless tobacco article. Alternatively, the smokeless tobacco articlecan have different thicknesses or dimensionality, such that a beveledarticle (e.g., a wedge) is produced or a hemi-spherical shape isproduced. In some cases, the smokeless tobacco article has a shieldshape.

In addition or in the alternative to flavorants being included withinthe mouth-stable polymer matrix, flavorants can be included on anexterior of the smokeless tobacco article 100.

In some cases, the smokeless tobacco article 100 or products 100A-0 canbe wrapped or coated in an edible or dissolvable film, which may besubstantially transparent or translucent. The dissolvable film canreadily dissipate when the smokeless tobacco article 100 is placed in anoral cavity.

One or more smokeless tobacco articles 100 can be packaged in a varietyof conventional and non-conventional manners. For example, a pluralityof smokeless tobacco articles 100 can be packaged in a container havinga lid. In some cases, a plurality of smokeless tobacco articles 100 canbe stacked and packaged in a paper, plastic, and/or aluminum foil tube.The packaging can have a child-resistant lid.

The smokeless tobacco article 100 can also include additional elements.In some cases, a mouth-stable polymer matrix including tobacco fiberscan be attached to a rod, tube, or stick. For example, FIGS. 8A-8Jillustrate tubes attached to a mouth-stable polymer matrix tips. FIG. 8Adepicts an embodiment of a smokeless tobacco article having a tip piece810 and a tube piece 820. The tip piece 810 can include the mouth-stablepolymer matrix having fibers and/or one or more additives within thepolymer matrix. The tip piece 810 can be sized and shaped to be at leastpartially received in an oral cavity. The tube piece 820 can be made ofany conventional polymer. During use the tube piece 820 can act asholder for the tip piece 810. The tube piece 820 and the tip piece 810can be attached by a snap-fit attachment feature 830, as shown in FIG.8B.

The tube piece 820 can be reusable. For example, multiple tip pieces 810can be packaged with a single tube piece 320 and a user can switch offthe tip pieces 810. In some cases, the tube pieces 820 can be intendedfor a single use. In some cases, the tube pieces 820 can includeflavorants within the tube. The flavorants can be adapted to be releasedwhen air is drawn through the tube 820. For example, FIG. 8C depicts atube including a flavor ribbon 822. FIG. 8D depicts a tube 820 includinga flavor strip 824 and a plurality of flavor beads 826. FIG. 8E depictsa tube 320 including a compressed mass 828 of flavor beads 826. In somecases, the inside of the tube can have structure adapted to alter theflow pattern of air drawn into the tube. For example, FIG. 8F depicts atube 820F having a series of steps and constrictions 840 adapted toalter the flow pattern of air drawn into the tube. FIG. 8F also depictsan alternative connection feature 830F.

FIG. 8G depicts an embodiment having a recorder-like shape. As shown, atip piece 810G is connected to the contoured tube piece 820. Forexample, the recorder-shaped tip 310G can be composed of a mouth-stablepolymer matrix that includes tobacco fibers, one or more sweeteners, andone or more flavorants. As shown, the tip piece 810G is sized and shapedto be at least partially received within an oral cavity of an adulttobacco consumer.

FIG. 8H depicts a similarly shaped smokeless tobacco article having aplastic recorder-shaped tip 810H that includes a reusable plastic part812 and a mouth-stable polymer matrix part 315 having tobacco fibersdispersed therein. FIGS. 8I and 8J depict embodiments havingalternatively shaped tip pieces 810I and 810J. FIG. 3I depicts anembodiment having a tapered tube 820I. FIG. 8J depicts an embodimenthaving vent holes at the non-tip end of the tube piece 820J.

In some cases, a system or kit of different tubes and rods and/ordifferent tips can be packaged together, each having the same type ofattachment features. Embodiments having each of the combinations of tipsand tubes or rods shown in FIGS. 8A-8J are contemplated.

Smokeless Tobacco Article Properties

The smokeless tobacco article 100 can provide a favorable tactileexperience (e.g., mouth feel). The smokeless tobacco article 100 canalso retain its shape during processing, shipping, handling, andoptionally use. As noted above, the smokeless tobacco article 100includes a mouth-stable polymer matrix that does not appreciablydissolve or disintegrate when placed in an oral cavity and exposed tosaliva. In some cases, the smokeless tobacco article 100 can have anelasticity allowing an adult tobacco consumer to work the product withinthe mouth. In some cases, the smokeless tobacco article 100 has at leastsome shape memory and thus can return to shape after being squeezedbetween teeth in an oral cavity. Working of the smokeless tobaccoarticle 100 within the oral cavity can accelerate the release of thetobacco constituents, additives, sweeteners, and/or flavorants withinthe mouth-stable polymer matrix.

During use, the smokeless tobacco article 100 can absorb saliva into thepolymer matrix and provide access to the tobacco in the polymer matrix.Physical activity, such as chewing of the smokeless tobacco article inthe mouth, can also accelerate the release of tobacco, tobaccoconstituents, flavors, and/or other additives in the smokeless tobaccoproduct. As the smokeless tobacco article is chewed, saliva can accessdifferent sections of the polymer-fiber matrix. The smokeless tobaccoarticle 100 can be chewed without significant and instantaneouspermanent plastic deformation. As the product is chewed, it can becomemore pliable and additional additives can become available for releaseinto the oral cavity. Some embodiments of the smokeless tobacco article100 can be adapted to remain non-sticky during and after use. Afterprolonged use, certain embodiments of the smokeless tobacco article 100will expand and become flatter. The smokeless tobacco article, however,can retain the essence of its original shape. The amount of deformationwill depend on the duration of use and an amount of mouth force used. Asthe product is used, it can increase in both weight and volume, due tothe swelling of the porous matrix with saliva. With greater the physicalmanipulation, the smokeless tobacco article 100 will have a greateramount of swelling and thus have a larger weight gain. In certainembodiments, the smokeless tobacco article 100 will having an increasein weight of between 4 and 75 percent when chewed by an adult consumerfor 30 minutes.

Referring to FIG. 9, the smokeless tobacco articles provided herein canhave a Shore M harness of at least 85, a Shore M hardness of at least86, a Shore M hardness of at least 88, a Shore M hardness of at least89, a Shore M hardness of at least 90, a Shore M hardness of at least91, or a Shore M hardness of at least 92. With increased heating timesand temperatures, the Shore M hardness can be increased, as shown by theprogressively larger bars. As shown, the Shore M hardness also increaseswith increased pressure during the pressing process. These pieces weresintered at 30, 40, and 50 minutes at 150° C. Longer sintering timeyielded higher durometers. Formulation was 2 parts 180 um particle sizeUHMWPE to 1 part 400 mesh tobacco by weight.

The smokeless tobacco article 100 can have a variety of colors. In somecases, natural and artificial coloring can be added to the mouth-stablepolymer before the polymer is formed into particles to form smokelesstobacco articles 100 having a predetermined color. Encapsulated flavorscan be added prior to the pressing process to create speckles, patternsor dots within the smokeless tobacco article.

Tobacco

By “tobacco” it is meant a part, e.g., leaves, and stems, of a member ofthe genus Nicotiana that cut, shredded, or otherwise processed to formfibers of tobacco plant tissue. Exemplary species of tobacco include N.rustica, N. tabacum, N. tomentosiformis, and N. sylvestris. For example,the tobacco particles can be made by comminuting tobacco stems. Thetobacco particles can include cellulose, lignin, lipids, hemicellulose,and other tobacco constituents.

Suitable tobaccos include fermented and unfermented tobaccos. Inaddition to fermentation, the tobacco can be processed using othertechniques. For example, tobacco can be processed by heat treatment(e.g., cooking, toasting), flavoring, enzyme treatment, expansion and/orcuring. Both fermented and non-fermented tobaccos can be processed usingthese techniques. In some cases, the tobacco can be unprocessed tobacco.Specific examples of suitable processed tobaccos include dark air-cured,dark fire-cured, burley, flue cured, and cigar filler or wrapper, aswell as the products from the whole leaf stemming operation. In somecases, the tobacco can include up to 70% dark tobacco on a fresh weightbasis.

Tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. Fermenting typically is characterized by high initialmoisture content, heat generation, and a 10 to 20% loss of dry weight.See, e.g., U.S. Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and5,372,149. In addition to modifying the aroma of the leaf, fermentationcan change either or both the color and texture of a leaf. Also duringthe fermentation process, evolution gases can be produced, oxygen can betaken up, the pH can change, and the amount of water retained canchange. See, for example, U.S. Publication No. 2005/0178398 and Tso(1999, Chapter 1 in Tobacco, Production, Chemistry and Technology, Davis& Nielsen, eds., Blackwell Publishing, Oxford). Cured, or cured andfermented tobacco can be further processed (e.g., cut, expanded,blended, milled or comminuted) prior to incorporation into the smokelesstobacco article. The tobacco can be long cut fermented cured moisttobacco having an oven volatiles content of between 48 and 50 weightpercent prior to mixing with the mouth-stable polymer and optionallyflavorants and other additives.

The tobacco can be prepared from plants having less than 20 μg of DVTper cm² of green leaf tissue. For example, the tobacco can be selectedfrom the tobaccos described in U.S. Patent Publication No. 2008/0209586,which is hereby incorporated by reference. Tobacco compositionscontaining tobacco from such low-DVT varieties exhibits improved flavorcharacteristics in sensory panel evaluations when compared to tobacco ortobacco compositions that do not have reduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g.,flue-cured, barn-cured, fire-cured, air-cured or sun-cured. See, forexample, Tso (1999, Chapter 1 in Tobacco, Production, Chemistry andTechnology, Davis & Nielsen, eds., Blackwell Publishing, Oxford) for adescription of different types of curing methods. Cured tobacco isusually aged in a wooden drum (i.e., a hogshead) or cardboard cartons incompressed conditions for several years (e.g., two to five years), at amoisture content ranging from 10% to about 25%. See, U.S. Pat. Nos.4,516,590 and 5,372,149. Cured and aged tobacco then can be furtherprocessed. Further processing includes conditioning the tobacco undervacuum with or without the introduction of steam at varioustemperatures, pasteurization, and fermentation. Fermentation typicallyis characterized by high initial moisture content, heat generation, anda 10 to 20% loss of dry weight. See, e.g., U.S. Pat. Nos. 4,528,993;4,660,577; 4,848,373; 5,372,149; U.S. Publication No. 2005/0178398; andTso (1999, Chapter 1 in Tobacco, Production, Chemistry and Technology,Davis & Nielsen, eds., Blackwell Publishing, Oxford). Cure, aged, andfermented tobacco can be further processed (e.g., cut, shredded,expanded, or blended). See, for example, U.S. Pat. Nos. 4,528,993;4,660,577; and 4,987,907.

The tobacco can be processed to a desired size. In certain embodiments,the tobacco fiber can be processed to have an average fiber size of lessthan 200 micrometers. In particular embodiments, the fibers are between75 and 125 micrometers. In some cases, the fibers are processed to havea size of 75 micrometers or less. In some cases, the tobacco includeslong cut tobacco, which can be cut or shredded into widths of about 10cuts/inch up to about 110 cuts/inch and lengths of about 0.1 inches upto about 1 inch. Double cut tobacco can have a range of particle sizessuch that about 70% of the double cut tobacco falls between the meshsizes of −20 mesh and 80 mesh.

The tobacco can have a total oven volatiles content of about 10% byweight or greater; about 20% by weight or greater; about 40% by weightor greater; about 15% by weight to about 25% by weight; about 20% byweight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” tobacco typically refers to tobacco that has an ovenvolatiles content of between about 40% by weight and about 60% by weight(e.g., about 45% by weight to about 55% by weight, or about 50% byweight). As used herein, “oven volatiles” are determined by calculatingthe percentage of weight loss for a sample after drying the sample in apre-warmed forced draft oven at 110° C. for 3.25 hours. The smokelesstobacco article can have different overall oven volatiles contents thanthe oven volatiles contents of the tobacco used to make the smokelesstobacco article. The processing steps described herein can reduce orincrease the oven volatiles content.

In some cases, the tobacco can be processed to include flavor componentsprior to construction of a molded article. Such “primary” flavorcomponents can be added, for example, by spraying tobacco with a flavorextract prior to combining the tobacco with a thermoplastic polymer andforming the smokeless tobacco article. In another example, flavor can beimparted to tobacco by combining solid or liquid flavor agents with atobacco material and incubating under suitable conditions, as described,for example, in previously incorporated application Ser. No. 10/982,248.Alternatively or in addition, a smokeless tobacco article can be furtherprocessed to add one or more “secondary” flavor components via capillaryaction, injection, or other introduction means, such that the flavorcomponents are added after construction of the article. In suchembodiments, smokeless tobacco articles could be flavored in accordancewith customer orders, resulting in increased control of inventory, forexample. In some cases, flavor can be added after the article is formedby placing the article under a vacuum and subsequently filling thearticle with a flavor by placing a flavor in the vacuum chamber.

Flavor can be provided by synthesized flavors, flavor extracts, plantmatter, or a combination thereof. Suitable flavors and flavor extractsinclude, without limitation, menthol, cinnamon, wintergreen, cherry,berry, peach, apple, spearmint, peppermint, bergamot, vanilla, coffee,mint oil from species of the genus Mentha, or other desired flavors.Flavors can also be provided by plant matter, e.g., mint leaves, whichtypically are 10% flavor oils and 90% insoluble fiber. Suitable plantmatter can be obtained from plants such as clove, cinnamon, herb,cherry, peach, apple, lavender, rose, vanilla, lemon, orange, coffee, orspecies of the genus Mentha. As further provided herein, flavor can alsobe provided by imitation, synthetic, or artificial flavor ingredientsand blends containing such ingredients. Suitable sweeteners include, forexample, sucralose, acesulfame potassium (Ace-K), aspartame, saccharine,cyclamates, lactose, sucrose, glucose, fructose, sorbitol, and mannitol.Liquid smoke or other heat activated flavorants also can be added toprovide additional flavor.

Additives

A variety of additives can be included in the smokeless tobacco article100. The additives can include alkaloids (e.g., nicotine), minerals,vitamins, dietary supplements, nutraceuticals, energizing agents,soothing agents, coloring agents, amino acids, chemesthic agent,antioxidants, food grade emulsifiers, pH modifiers, botanicals (e.g.,green tea), teeth whitening (e.g., SHRIMP), therapeutic agents,sweeteners, flavorants, and combinations thereof. In certainembodiments, the additives include nicotine, sweeteners, and/orflavorants.

The smokeless tobacco article 100 may optionally include otheradditives. For example, these additives can include non-nicotinealkaloids, vitamins, dietary minerals, other dietary supplements, and/ortherapeutic agents. For example, suitable vitamins include vitamins A,B1, B2, B6, C, D2, D3, E, F, K, and P. For example, a smokeless tobaccoarticle 100 can include C-vitamins. Suitable dietary minerals includecalcium (as carbonate, citrate, etc.) or magnesium (as oxide, etc.),chromium (usually as picolinate), and iron (as bis-glycinate). One ormore dietary minerals could be included in a smokeless tobacco articlewith or without the use of other additives. Other dietary supplementsand/or therapeutic agents can also be included as additives.

The smokeless tobacco article 100 can also include fillers such asstarch, di-calcium phosphate, lactose, sorbitol, mannitol, andmicrocrystalline cellulose, calcium carbonate, dicalcium phosphate,calcium sulfate, clays, silica, glass particles, sodium lauryl sulfate(SLS), glyceryl palmitostearate, sodium benzoate, sodium stearylfumarate, talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerolmonostearate, propylene glycol monostearate, and acetylatedmonoglycerides), stabilizers (e.g., ascorbic acid and monosterolcitrate, BHT, or BHA), disintegrating agents (e.g., starch, sodiumstarch glycolate, cross caramellose, cross linked PVP), pH stabilizers,or preservatives. In some cases, the amount of filler in the smokelesstobacco article 100 is limited to less than 10 weight percent in sum. Insome cases, the amount of filler in the smokeless tobacco article 100 islimited to be less than 5 weight percent in sum. In some cases, thefillers are mouth stable. In some cases, the fillers can dissolve ordisintegrate during use and thus result in a smokeless tobacco articlethat becomes more pliable during use.

OTHER EMBODIMENTS

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. For example, the mixture of particles can beselectively heated with a laser. Other aspects, advantages, andmodifications are within the scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed.

What is claimed is:
 1. A method for making a smokeless tobacco article,comprising combining thermoplastic polymer particles with tobaccoparticles to form a mixture of particles; compressing the mixture ofparticles within a pressing apparatus to form the mixture into apredetermined shape; releasing pressure on the mixture such that themixture retains the predetermined shape; and heating the mixture to atleast partially melt at least some of the thermoplastic polymerparticles and form a matrix of polymer and tobacco particles.